Asia Food & Beverages Report (May/June 2021 issue)

Packaging & Technology News
CHEESE PRODUCTION LINES
Tetra Pak introduces 14 state-of-the-art production lines
for Cheese Manufacturers
Tetra Pak has recently announced the development of 14 new Best
Practice Lines (BPLs) for cheese manufacturers, with the latest one
launched specifically for Cottage Cheese. The other cheeses that will
benefit from these BPLs include Mozzarella, Semi-hard cheese, Cheddar,
and Fresh cheese production. Together, these cheese types make up
79% of all cheese volumes and have a CAGR of 3% (2021-2025).
Leveraging on Tetra Pak’s more than 50 years of experience in the
cheese category, which is also the biggest dairy food segment in the world
at 42% share (27 billion kg), the new BPL concepts provide a complete
production solution for customers, optimised to fit their needs. The
processing lines utilise proven equipment combined with industry-leading
expertise to create a safe and easy route to profitable cheese production
with a higher yield, while incorporating the traditional cheesemaking
techniques. The hygienic production process enables a longer product
shelf life, as well as consistent and replicable quality. Sustainability is
also a factor, with solutions focusing on reducing water, steam and power
consumption.
Fred Griemsmann, Vice President Cheese & Powder Systems at Tetra
Pak said, “Cheese is consumed on every continent around the world,
and consumer appeal shows no signs of abating. In fact, it’s quite the
opposite.
We’ve expanded and deepened our expertise and knowledge over the
last decade, consolidated our proficiency and sites in the US, and recently
invested €25 million (US$30.6 million) to create a world-class cheese
production centre in Poland. With 50 years of expertise, we are the only
supplier for complete solutions from milk intake, cheese production,
through to packaging. This provides us with a sophisticated toolkit that
enables us to tailor solutions to be completely suited to the customers’
needs, and we are so confident in these new Best Practice Line solutions
that they come with performance guarantees.”
The most popular cheese is yellow cheese, accounting for a 34% share of
the global cheese volume, and includes both hard and semi-hard cheese
varieties. The Tetra Pak® draining belt portfolio provides continuous
production of fused and stirred Cheddar and Pasta Filata cheese types.
These enclosed belt systems are designed to automatically drain, acidify
and texture, mill, salt and mellow cheese curd, similar to the traditional
cheese method. Fines from whey are captured by a fines saver screen
integrated in the belt machine maximising yield. This design allows for
consistent curd production resulting in uniform acidity, moisture, salt
concentration and loading rate.
The second most popular cheese category is Mozzarella. With a focus
on yield improvement, product quality, and reduced environmental impact
for the production of Mozzarella, the Tetra Pak® Cooker Stretcher DDA
dry cooker uses a (patented) heated auger and dimpled heated jacket
technology to heat the product indirectly resulting in higher fat retention in
the final product. Employing 9 independent heating zones with integrated
ingredient addition capabilities, it offers producers unprecedented control
of the cooking process.
Tetra Pak´s draining and forming systems set the benchmark in the
industry. The Tetra Pak Blockformer system - where curd is compacted
in a series of vacuum and pressure relief cycles - employs an advanced
design enabling it to run Parmesan cheese as well as Cheddar cheese.
Meanwhile, Tetra Pak® Casomatic systems efficiently drain and form
semi-hard cheese and promote high-quality whey production. These
reliable systems maximise yield with a highly controlled process that
eliminates weight and moisture variations in the final cheese product.
The hygienic design enables long production runs and short cleaning
cycles to optimise uptime.
COVID-19 has shifted consumer behaviours in many ways and
cheese is no exception, with a third (36%) of consumers saying they
have significantly increased their intake of cheese throughout the global
pandemic. This is due, in part, to the fact that we are spending more
time at home, providing us with increased opportunities to eat cheese,
such as when watching TV (36%), with a drink (35%) or as a quick lunch
(35%). People are well-aware of the benefits of cheese, acknowledging
that it is healthy (56%), nutritious (51%) and high in protein (42%) and
calcium (41%).
It is apparent that there is real demand from consumers to know the
origins of their food, with an overwhelming majority (77%) expressing an
interest in the process of cheese production, specifically the ingredients
and where they are from (72%), where the product is made (52%), the
heat treatments used (41%) and the sterile production (37%). Over a third
(36%) also place particular value on environmentally friendly packaging.
Griemsmann added, “Cheese has been an essential part of our diet
for centuries and it is set to remain so for many years to come. People
are becoming more adventurous in terms of taste and texture, and
Tetra Pak has the facility to accommodate this, ensuring that there is no
compromise on the overall quality of the end result.”
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43 Asia Food & Beverages